Water adsorption process



Dec. 15, 1964 ADSORBATE s. c. EAsTwooDq ETAL 3,161,488

WATER ADSORPTION PROCESS Filed Jan. 18, 1961 CONCENTRATION IN ADSORBENT VLENGTH OF BED INLET FLUID CONTA ING COMPONENT TO BE -SEFARATED INVENTORS SYLVANDER C. EASTWOOD LUTHER J. REID. JR.

ALBERT B. SCHWARTZ ATTORNEY I EXIT FLUID United States Patent e O 3,l6l,488 WATER ABSRPTIN PRCESS Sylvander C. Eastwood, Woodbury, and Luther 3. Reid, r., West Deptford Township, Gloucester 3, i d ASS Patentedec. 15, 1964 ICC i the dehydration of hydrocarbons.

provide a greater volumetric adsorption capacity as comparedto the use of a single adsorbent. Y n v n 5 Another object is to provide an adsorption process for gqlig tl'ngfgc the simultaneous dehydration and recovery of liquid hy- Inc., a corporation of New York drarijns ffompaural, gas' Filed Jan. 18, 1961, Ser. No. 33,413 Additional objects will become apparent hereinafter.

9 Claims. (Cl. 55-30) Our invention will be more fully understood by refer- 10 ence to the appended drawings, wherein:

This invention relates to a novel adsorption process. FIG. 1 is a schematic representation of the dynamics More particularly, this invention relates to an adsorption occurring in an adsorption process; and process for the separation of one or more components FIG. 2 is a schematic diagram showing one embodifrom a stream of Huid containing such components, this ment ofthe process of our invention. process comprising passing the streamv successively An adsorption process conveniently may be pictured through two adsorbent-containing zones, the first zone conas shown in FlG. l. As the gas flows continuously taining adsorbent having a high volume porosity and a through the bed containing adsorbent the adsorbate concomparatively high average pore diameter, the second centration will build up in the bed to thereby form a zone containing an adsorbent having pores of comparawave as shown in zone Y. At the leading edge of the tivelysrnall average pore diameter. Wave the adsorbate concentrations in both the gas stream `The usual adsorbents used to effect selective separaand the adsorbent are low. In contrast, at the trailing tion vary considerably, both as to their compositions, edge of the wave the concentrations tend to be rather crystallinities, and pore structures. The degree of specihigh and frequently will be at the saturation concentra iicity of a particular adsorbent will depend upon a nurntion. The adsorbate concentration in the adsorbent is ber of factors, such as the nature of the surface, the type high and comparatively constant behind the trailing edge of pore structure, etc. Typical commercial adsorbents inof the Wave. This is illustrated by zone X. The length ciude fullers earth, bauxite, synthetic aluminas, acidof the adsorption wave will be dependent upon a number treated clays, magnesia, silica gel, silica-alumina, carbon, of factors such as the particular adsorbent used, the cornandthe like. Some of the physical properties and also the position of the gas stream, the velocity of the gas stream, water adsorption capacity for a number of these comthe temperature and pressure under which the adsorption rnercial adsorbents are given in Table I. is carried out, etc.

TABLE I Water Adsorption Capacity, Packed Pore Porosity, Average lbs. H2O/cu. ft. Bed Density, Volume, Percent Pore lbs/eu. ft. cc./g. Volume Diameter,

Angstroms 10% 20% 40% 80% BH1 RHl R111 RHI sinea-Aiumina 51 0,'36 45 22 6.3 5.4 11.1 18.2 silica Gel 47 0.37 44 22 2.9 4.9 10.2 17.2 ActivatedAlumina-i-- 42 0.56 64 71 2.9 4.0 6.2 13.2 Activated Alumina-2- 55 0. 34 53 50 2. s 3. 6 5. 4 15. 3 Activated Carbon- 34 0.71 59 29 i Relative Humidity. 2 Approximately 97% SiOz and 3% A1203.

An adsorbent which exhibits a desirably high eiiiciency In accordance with ourinvention, we have found that when used with streams highly concentrated with the a very efficient and economical adsorption process may component to be removed but which exhibits a low etiibe secured when an adsorbent having a high porosity and ciency at lower concentrations, must be used in exorbitant 50 a comparatively large average pore diameter is usedin amounts if used alone, in order to effectively remove the an initial zone and an adsorbent having pores of small desired component. This renders the removal process exaverage pore diameter is used in a secondary zone. pensive and inefcient. VYet the use of other types of The adsorbent to be used in the initial zone of Contact adsorbents,'i.e., adsorbents offering good eiiiciencies at low should have an average pore diameter of from about 30 concentrations, such as silica-alumina, Silea-magnesia, to 100 angstroms. The average pore diameter is deter- .silica-zirconia, etc., to effect the entire removal process is mined-on the assumption that the pores of the catalyst esalso Aquite expensive because of the comparative ineisentially are cylindrical. Accordingly, the average diamciencies of such adsorbents when used at the initial higher p eter of the pores of a given adsorbent are related to the concentrations. pore., volume and surface area by the equation:

Accordingly, it is an object of our invention to provide 4V animproved adsorption process.

Another object is to provide an adsorption process for Y Vthe eticient and economic selective separation of one or Where V is fhg volume ofthe pores in `Cubicntin-eu-,-'S more COmPGle-DS from a Stream CQDaIIDghQS COm- `VA. is the surface area in square centimeters, and d is the PODQHS! Y 55 diameter in centimeters. This equation makes use of the A further object is to provide an improved adsorption total pore volume and the surface area of the adsorbent. process whereby the adsorption capacity of a given size (A detailed discussion of how average pore diameterV adsorbent bed will be markedly increased. iS `determined is given in the text edited by P. H. Em-

Yet another object is to provide an adsorption process mett 'andrentitled Catalysts, Volume I, at page 56, 1954- wherein Vtwo adsorbents aroused successively to thereby ed., VReinhold `Publishing Corporation, New York.)

v The adsorbent to be used `in the initial zone of con-V tactil should also have a high volume porosity,

2? preferably from 50 to 75 percent volume, but in any event in excess of 45 percent voiume. In referring to porosity as percent volume we exclude voids between particles. Use of this term makes it unnecessary, when comparing upon the particular system being processed. For example, in the dehydration of air the preferred pressure range is from about zero to 200 p.s.i.g., Whereas in the dehydration of hydrocarbons such as ethylene, propylene, butaditerent adsorbents, to correct for different skeletal den- 5 diene, acetylene, and the like (prior to using such hydrosities and for variations in void space due to shape of carbons as raw materials for the manufacture of chemiparticles. Porosity refers to pores in the initially formed cals and polymers), the preferred pressure range is from gel and does not include pores introduced by shaping 100 to 600 p.s.i.g. For simultaneous dehydration and techniques such as pelleting and extruding. recovery of liquid hydrocarbon from natural gas, the

For the secondary zone of contact which zone is to rel0 preferred range is from about 500 to 2000 p.s.i.g. move the desired component from the stream when such The flow rate of the fluid through the adsorbent will component is present in comparatively low concentration, also vary, depending upon the particular separation being it is imperative that the adsorbent used have pores of small eifected. In general, the flow rate should be from about average diameter, i.e., less than 30 angstroms. 0.5 to 600 feet per minute. When the fluid is a gas the Thus, in accordance with our invention the first adsorbpreferred tlow rate is from about 3 to 600 feet per minent zone will contain an adsorbent having a high volume ute. For a liquid tluid, a flow rate of from about 1 to porosity preferably from about 50 to 75 percent volume 2() feet per minute is preferred. but at least in excess of 45 percent volume, and having The process of our invention may be carried out in an average pore diameter of from about 30 to 100 angstatic or moving bed systems. In non-moving bed sysstroms, whereas the second zone will contain an adsorbtems the two zones of the adsorbent may be housed in a ent that is effective for the removal of the remainder of single vessel or may be disposed in separate vessels. For the desired component, which component will be present a continuous system, either two continuous beds or one in relatively low concentration in the stream containing continuous and one static bed are required, with the such component, so that such adsorbent will have pores gas or liquid stream owing therethrough in series. of small average diameter, preferably of the order of It will be understood that whereas FIG. 2 shows a from l5 to 25 angstroms, but in any event, less than downiiow arrangement in which the fluid irst contacts about angstroms. the adsorbent having at least 45 percent volume porosity By virtue of our invention, the combination of two and an average pore diameter of from 30 to 100 angsuch adsorbents will increase the adsorption capacity of SOmS and hon COHHCS the adsorbent having poros of a given size bed. Further, our invention permits the use 30 ess than 30 angstrom average diameter, our invention may of a relatively low cost adsorbent in the first zone (for also bo utilized in an UPoW arfangomon That is, Ud removal of high concentrations of the component to be may be infoduood at U12 bottom 0f the Column and C011- adsorbed). Further, by using the process of our inventacted rst with the large-pore-volume adsorbent and then tion there results a higher volumetric adsorption capacity With the Smau Pore damodor adsorbent located Il the as compared to a similar process using a single adsorb- UPPor Portion of the 'Column ent, because adsorbents which have small pore diameters After the adsorption Cycle 1S Completo the adsorbent will generally also have a low pore volume may be regenerated in any one of the usual conventional It will be understood that the process of our invention methods Such as thermal, regorrorarlonwrrh a preheated has a Wide Variety of applications- For example, our purge gas, pressure reduction with or without a purge gas, process may be used in conjunction with either a vapor ge of a purge gas alone (to requce the primal ressurp or liquid phase stream containing a component that is splagegent of that sotrbatelfwnhh another mole readily desired to be selectively separated therefrom. Typical o Sr e componen. e c' a; ree tower type .system is used, one tower is on adsorption, another is being reapplications include .the recovery 'of valuable volatile generated, and the third is being cooled solvents from processing streams, simultaneous dehydra- A comparison of the Suitability of Herent S1ca ooo ano r ooovery or hydrocarbons from natural gas the alumina adsorbents for the first zone (to remove the high Purloalon of gases Such as, igthe removal of hydrogen concentration of component from the stream) and for Sulde from natural gas, the SoreCVo Separation 0f hYdrO- the second zone (to remove the remaining lower concencarbons, the drying of organic liquids, the dehydration of tration of component from the stream), is afforded by a natural gas, hydrocarbon streams, or air, etc. consideration of the data in Table II.

TABLE II Comparison ofPropertes of Various Silica-Alumina l Adsorbents Adsorbent Packed Pore Porosity, Average Pore Watlbsl?gghxi'tlgclty N iiniber Density, Volume, Percent Diameter, Capacity, lbs. lbs/cu. it. tze/g. Volume Angstroms H20/cu. it. bed

10% RH 2 20% RH 2 40% RH 2 80% RH 2 49 0.37 46 22 3.5 5.6 11.5 18.3 18.2 42 0. 49 52 2s 2. o 4.1 8.7 20. 4 20. s 40 0.54 55 3i 1.7 3.1 7.1 21.5 21.6 35 0.67 59 4o 1.4 2.4 5.0 23.5 23.5

1 97% sioi, 3% Aitor. 2 Relative Humidity.

The temperatures and pressures at which our adsorption process may be carried out will naturally vary, depending upon the specific type of selective separation desired. In general, We prefer that the adsorption be carried out at a temperature of from about to 200 F. A more preferred range is from about 20 tov 175 F. The adsorption may be carried out at atmospheric pressures or at elevated pressures and generally will be from atmospheric up to about 2000 poundsv per square inch.

It will be noted that when drying air that is at relative humidity, the pore volume of the adsorbent is essentially filled under equilibrium conditions. However, for etfective drying at lower relative humidities only adsorbents l and 2, namely adsorbents having average pore diameters less than 30 angstroms and small individual pore volumes, are genuinely effective. This is borne out for air at much lower relative humidities as 40, 20 and 10 percent.

The optimum ranges' of pressures will vary depending 75 In accordance with Vour invention, when an adsorbent eiective at lower concentrations, such as adsorbent 1, i.e., having a pore diameter of 22 angstroms, is used in successive combination with an other adsorbent effective at higher concentrations such as adsorbent 3, i.e., having a ing examples illustrate such hydrocarbon recovery under conditions of atmospheric pressure.

EXAMPLES 2-4 These examples illustrate the application of our invenporosity of 55% volume and an average pore diameter of 5 tion to the adsor tion of entame from a l pentane-methane 31 angstroms, an unusually effective and efficient adsorpp l P tive separation results. This eifect is illustrated by the fol- 2lsgnlggnagl gg; jgrrl; ioymgt esamples Au parts are by Weight unless Otherwse i entane downiiow through the adsorbent bed. The total m 10a e f volume of adsorbent used was held constant for each test, EXAMPLE 1 le regardless of Whether a one or two-adsorbent system was Dynamic adsorption tests were made with adsorbents used- The adsorPtOn commu eonslsted o? a 51X foot 1 and 3 of Table II. In enother test, our process was aluminum tube having a diametenof 1%4 inches. The compared with the above adsorption tests by using adsoy tests were carried out at atmospheric pressureand 80 F. ent 3 in the initial Zone (to remove the high concentra 15 The gaseous ow rate was 0.19 standard cubic foot 1 per tion of water in the stream) and by using `adsorbent: 1 in msmte- The length of the adserptlon eyele Wee twenty the second zone (to remove the lower concentration of mmlles Dynamlc adsorption tests were made Wlth each remaining Water in the stream). The tests were carried of single adsefbents A B C and D 0e Table I IL Our out at atmospheric pressure and as indicated in FIG. 2, two'adsorbent Process Was compared with the Smgle ad' that is, by passing an air stream of 80% relative humidity 20 sorbent dynamic tests' Thus m Example 2 the adsoeent downow through a three foot bed of asorbent main; bed consisted of 75 volume percent adsorbent A, silicatained at 80 F. The column containing the adsorbent alumina (31 A average Pore dlamete Placed 1n thefop had a daimeter of 0 75 inch The Column was immersed part of the bed, and 25 volume percent adsorbent B, silica in Water to maintain isothermal conditions. The flow rate dumme (22 A average pers. dlame placed m the bot was 40 feet per minute. In each case the run was con- 25 tem eert of the bed' Slmllarly m Example 3 the bed timed until the dew point of the euent reached 40 R contained 75 volume percent adsorbent A and 25 volume The amount of Water adsorbed is expressed as the dynamic irglt lerlalenfgeoeeldne dsopton Capaclty The results Obtamed were as fol' tained 50 volume percent adsorbentC (activated alumina) OWS and 50 volume percent adsorbent B.

The results are tabulated in Table IH. It Will be noted Diitnagllclgsoptiggtthat in both Examples 2 and 4 the actual amount of Adsoreent OfyBed p pentane adsorbed considerably exceeds the calculated value. Thus, Example 2 shows an adsorption of 146 Experimental Calculated grams of pentane, whereas the expected adsorption by calculation (75% of 135 plus 25% of 141) is only 136 67% of adsorbent 3 'in top zone; 33% of grams. Similarly, Example 4 shows 133 grams of pentane adsorbentiin bottom zone (two wees)- 9 5 8-8 adsorbed, as compared to a calculated expectation of only 121 grams (50% of 101 plus 50% of 141).

TABLE III Dynamic Adsorption of Pentane From ZVIethane-Pentane Stream Locat'on P t A All-Pebltne P t l i orosi v Exletnple adsorbent' in Adsorbcnt perceni: Purge Sor e g Regclilviel,

Column Ident. Vol. Diam., Y percent A; Experi- Calcuniental lated 100%v01-Silica-Al1m1ina Tigugh- 56 31 135 62 Do --dol- 22 141 64 100% vol.Act.Alu1ni'na-l ,do 64 71 101 46 Y 193% vol. giliea Gel. .5.-.- do 44 22 127 57 2 {folfiielflma Bt' i? Si l 146 G7 75 Ls'i -Ai T 56 si 3 {Qggt-istiiitti/ilalieiilelii-- trage. i9 i 143 65 5 nao l 4 {sogggisiiict-iuininua Boi) 45 i2 i 133 121 61 It will be noted that lby using the two-zone process of our invention there were adsorbed v9.5 pounds per cubic foot of adsorbent. This compares to a calculated value of 8.8 pounds per cubic foot which would` have been obtained if the adsorption capacity of the two zones were additive. Accordingly, it will be seen that the process vof our invention confers a synergistic effect; that is, the resulting adsorption efficiency is greater than what would be expected by calculation. f Y t v Our invention also nds application in the simultaneous dehydration and recovery of liquid hydrocarbons from natural gas. Natural gas consists chiey of methane, along with lower concentrations of etliane, propane, butane,

, pentane, hexane, and perhaps some heavier hydrocarbons.

Usually some carbon'dioxide,vr nitrogen, and Water are `also present. jHydrocarbons generally recovered in the ladsorption unit are propane and heavier. The follow#v` `4 75 Although the examples presented as illustrative of our invention have shown the use of non-crystalline adsorbents such as silica-alumina, activated alumina, silica gel, and the like, our inventionl also nds application using adsorbents having crystalline structure, such as the aboveillustrated.silica-magnesia, also clays and aluminas having Well deined crystalline structures are suitable adsorbent materials for use in our invention, provided that such materials conform to the required porosities and average pore diameters described herein. Y

-It will be understood that variations can be made without departing` Yfrom the spirit and scope of our invention.

Having thus described our invention, what we desire to secure and claim by Letters' Patent is:

alergias 1. A method of selectively and economically separating a component from a stream of iluid containing said component comprising rst passing said stream into contact with a solid porous adsorbent having a porosity of from about 50 to 75 percent volume and an average pore diameter of from about 30 to 100 angstrom units, and then passing said stream into contact with a solid porous ad sorbent having an average pore diameter of from 15 to 25 angstrom units.

2. The method of claim 1 wherein said stream is gaseous. v

3. The method of claim 1 wherein said stream is liquid.

4. A method of removing moisture from a gas containing said moisture comprising tirst passing said gas into contact with a solid porous adsorbent having a porosity of from about 50 to 75 percent volume and an average pore diameter of from about `30 to 100 angstrom units, and then passing said gas into contact with a solid porous adsorbent having an average pore diameter of from 15 to 25 angstrom units.

5. The method of claim 4 wherein said gas is air and said method is carried out at a temperature of from about 20 to 175 1F. and at a pressure of from about zero to 200 pounds per square inch gage.

6. A method of removing moisture from a hydrocarbon stream containing said moisture comprising first passing said stream into contact with a solid porous adsorbent having a porosity of from about 50 to 75 percent volume F.; and an average pore diameter of from about to 100 angstrom units, and then passing said stream into contact with a solid porous adsorbent having an average pore diameter of from 15 to 25 angstrom units.

7. The method of claim 6 carried out at a temperature of from about 20 to 175 F. and a pressure of from about 100 to l600 pounds per square inch gage.

8. A method of simultaneously removing moisture and recovering liquid hydrocarbons from a natural. gas stream, this method comprising first passing said stream into c011- tact with a solid porous adsorbent having a porosity of from about to 75 percent volume and an average pore diameter of from about 30 to 100 angstrom units, and then passing said stream into Contact with a solid porous adsorbent having an average pore diameter of from 15 to 25 angstrom units,

9. T he method of claim 8 carried out at a temperature of from about 20 to 175 P. and a pressure of from about 5 00 to 2000 pounds per square inch.

References Cited in the file of this patent UNITED STATES PATENTS 2,093,454 Kistler Sept. 21, 1937 2,698,305 Plank et al Dec. 28, 1954 2,799,362 Miller July 16, 1957 2,910,139 Matyear Oct. 27, 1959 2,944,627 Skarstrom July 12, 1960 UNITED STATES PATENT OFFICE CERTIFICATE 0F CORRECTION Patent Ne. 3,161,488 Deeembel^ 15, 1964 Sylvander C. Eastwood et al.

It is hereby certified that error appears in the above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

Columns 3 and 4, TABLE II, heading to last column, for "Theoretical Maximum Capacity, lbs. H O/cu. ft. bed" readA Theoretical Maximum Adsorptive Capacity, lbs. H2O/cu. ft.

` bed columns 5 .and 6, TABLE III, under the column heading ','Adsorbent", line 6 thereof., for "Z5 Vol." read 25% vol Silica-Alumina Signed and sealed this v3rd day of Augustv 1965.

(SEAL) Attest:

ERNEST W. SWIDER EDWARD J. BRENNER Attcsting Officer Commissioner of Patents 

1. A METHOD OF SELECTIVELY AND ECONOMICALLY SEPARATING A COMPONENT FROM A STREAM OF FLUID CONTAINING SAID COMPONENT COMPRISING FIRST PASSING SAID STREAM INTO CONTACT WITH A SOLID POROUS ADSORBENT HAVING A POROSITY OF FROM ABOUT 50 TO 75 PERCENT VOLUME AND AN AVERAGE PORE DIAMETER OF FROM ABOUT 30 TO 100 ANGSTROM UNITS, AND THEN PASSING SAID STREAM INTO CONTACT WITH A SOLID POROUS ADSORBENT HAVING AN AVERAGE PORE DIAMETER OF FROM 15 TO 25 ANGSTROM UNITS. 